Dough Sheeter Cutter Roller

ABSTRACT

An improved dough sheeter having a pair of counterrotating sheeter rollers and a cutter roller rotating against a front one of the sheeter rollers to cut a pattern into a sheet of dough therebetween. The improvement is the cutter roller being formed from an oil-impregnated wear resistant plastic that results in a much longer cutter life. The dough sheeter&#39;s cutter roller may have axial shaft, a pair of cutter lift arms including a U-shaped end, and a pair of needle bearing assemblies, each needle bearing assembly located on a corresponding end of the axial shaft. Also disclosed is a method of manufacturing a cutter roller for a dough sheeter where the crown is formed before the cutting pattern is cut into the cutter roller.

CROSS REFERENCE TO RELATED APPLICATION

This non-provisional patent application is a divisional of U.S.application Ser. No. 11/829,858, filed Jul. 27, 2007, now pending, whichclaims the benefit of U.S. Provisional Patent Application Ser. No.60/834307, filed on Jul. 27, 2006, entitled “CUTTER MADE WITH IMPROVEDBEARING SYSTEM, FORMED FROM OIL-IMPREGNATED PLASTIC, AND IMPROVED METHODOF MAKING SAME”, the entire contents of which are hereby incorporated byreference.

FIELD OF THE INVENTION

This invention relates generally to machinery used to produce Mexicanfood products such as chips or tortillas and, more particularly, to adough sheeter cutter roller.

BACKGROUND OF THE INVENTION

In the Mexican food industry, tortillas, chips, and the like, arecommonly formed by sheeting a mass of dough, or masa, into a sheetbetween a pair of counterrotating sheeter rollers, stripping the doughfrom the back roller (e.g. with a wire) so that it adheres only to thefront roller, and then cutting a pattern from the sheet by rotating aso-called cutter roller against the surface of the front roller.

The patterned sheet is then stripped from the front roller (e.g. with awire), with the product pieces falling down onto a conveyor belt, andwith the surrounding web of “rework” masa, if any, returning to thehopper above the two sheeter rollers to be recombined with fresh masa.

A typical dough sheeter and its cutter roller are disclosed in U.S. Pat.No. 6,530,771 entitled “Rotary Cutter Handling System”, which patent isassigned to the assignee of the present invention and herebyincorporated by reference as if fully set forth herein. A typical cutterroller is also depicted in U.S. Design Pat. No. Des. 391,125 without itsstainless steel shaft, the entire disclosure if which is herebyincorporated by reference as if fully set forth herein. This particulardesign patent depicts a cutter roller that cuts a fish-shaped productpattern into the dough sheet, but more conventional cutter rollersproduce triangular chips or round tortillas.

The cutter roller usually has a stainless steel shaft pressed throughits length. Conventionally, as shown in FIGS. 1-3, the cutter roller hasbeen supported between two spaced arms 20 (only one is shown), thestainless steel shaft of the cutter rotating with metal-to-metal contactwithin a brass bushing 30 that fits into a U-shaped end 21 of each liftarm 20.

Some cutter rollers have had their cutting portions made from brass, butthey are relatively expensive to manufacturer. More recently,conventional cutter rollers have often been made from plastics likeUHMW, a plastic that is relatively soft and that wears quickly, orDELRON®, a plastic that is relatively hard and brittle that chips andalso wears quickly. In either case, because the walls of the patternformed in the UHMW or DELRON® cutter tend to wear against the surface ofthe sheeter roller, the cutter roller has a short life span that can beas low as only 1-3 months.

There remains a need therefore for a cutter roller with an improvedbearing system and that is inexpensive to manufacture and has a longlife span.

BRIEF SUMMARY OF THE INVENTION

In a first aspect, the invention may be regarded as an improved doughsheeter having a pair of counterrotating sheeter rollers and a cutterroller rotating against a front one of the sheeter rollers to cut apattern into a sheet of dough therebetween, the improvement comprisingthe cutter roller being formed from an oil-impregnated wear resistantplastic.

In a second aspect, the invention may be regarded as a dough sheetercomprising: a cutter roller having an axial shaft with ends extendingfrom opposite ends thereof; a pair of cutter lift arms including aU-shaped end; a pair of needle bearing assemblies, each needle bearingassembly located on a corresponding end of the axial shaft of the cutterroller, wherein each needle bearing assembly further includes a housingassembly having an outer race, wherein the outer race of each housingassembly has notches which engage the U-shaped end of a correspondingone of the cutter lift arms. The cutter roller is preferably formed froman oil-impregnated plastic.

In a third aspect, the invention may be regarded as a method of forminga cutter roller for a dough sheeter comprising the steps of: providing aroller blank of a desired diameter; boring an axial aperture in theroller blank; installing a shaft in the axial aperture of the rollerblank; creating a crown on the roller blank by removing material fromthe roller blank to create a crowned roller blank; and machining thecutting pattern into the crowned roller blank to create a finishedcutter roller. The roller blank is formed from an oil-impregnatedplastic.

It is an object of the invention to provide an improved dough sheeter.

It is a further object of the invention to provide an improved cutterroller.

It is a further object of the invention to provide an improved interfacebetween the cutter roller and support therefore.

It is a further object of the invention to provide a cutter roller thatis inexpensive to manufacture.

It is a further object of the invention to provide a longer lastingcutter roller.

The just summarized invention may be better understood by reviewing thepreferred embodiment disclosed in the following description and relateddrawings. it is understood that changes in the specific structure shownand described may be made within the scope of the claims, withoutdeparting from the spirit of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention and its various embodiments can now be better understoodby turning to the following detailed description of the preferredembodiments, which are presented as illustrated examples of theinvention defined in the claims. It is expressly understood that theinvention as defined by the claims may be broader than the illustratedembodiments described below or illustrated in the figures, of which:

FIG. 1 is a top view of a cutter roller lift arm, two such lift armsbeing employed in a typical dough sheeter;

FIG. 2 is a side elevation view of the cutter roller lift arm of FIG. 1;

FIG. 3 is an exploded perspective view of the cutter roller lift arm ofFIGS. 1 and 2 and a conventional brass bushing which fits into the liftarm and rotatably engages a shaft of a cutter roller (not shown);

FIG. 4 is an end view of a needle bearing and housing assembly to becombined with the shaft of a cutter roller according to an embodiment ofthe invention;

FIG. 5 is a side view of the needle bearing and housing assembly;

FIG. 6 is a perspective view of the needle bearing;

FIG. 7 is an exploded perspective view of the needle bearing and housingassembly;

FIG. 8A is exploded perspective view a improved cutter roller lift armwhich receive the needle bearing and housing assembly;

FIG. 8B is a perspective view of the improved cutter roller lift arm andthe needle bearing and housing assembly;

FIG. 9 is a side view of the improved cutter roller lift arm and theneedle bearing and housing assembly;

FIG. 10 shows a cutter roller 100 which has cutting walls 111 definingproduct shapes 112 (e.g. chips and tortillas) and may be made accordingto an embodiment of the present invention; and

FIG. 11 shows the steps of a preferred method of manufacturing a cutterroller according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Many alterations and modifications may be made by those having ordinaryskill in the art without departing from the spirit and scope of theinvention. Therefore, it must be understood that the illustratedembodiment has been set forth only for the purposes of example and thatit should not be taken as limiting the invention as defined by thefollowing claims.

FIGS. 4-9 show a new needle bearing 50 to be combined with the shaft ofa cutter roller according to an embodiment of the invention. As shown,an outer race 60 of the preferred needle bearing 50 has side flats 61that allow it to slidably engage a new pair of support arms or cutterlift arms 70 as best shown in FIGS. 8-9. The new cutter lift arms 70have an enlarged U-shaped end 71 that is provided in order to fit thelarger size of the inner and outer races of the needle bearing 50. Otherembodiments may be used that permit the needle bearing configuration tobe used in a retrofit fashion with a standard arm like that shown inFIG. 3, but there may be issues of sizing and durability if the needlebearing's races are designed to fit into an existing arm.

FIG. 10 depicts a cutter roller 100 having a main body 110 and aplurality of cutter walls 11 which are formed therein (e.g. via a CNCmilling process) to provide a plurality of cutter patterns 112. Asdescribed above, typical cutter rollers are manufactured from UHMW ornylon, materials which are either quite soft or quite brittle such thatthey tend to wear against the sheeter roller and require replacement inas little as 1-3 months.

It has been discovered that a significantly improved life span can beachieved by manufacturing the cutter roller 100 from an oil-impregnatedplastic such as NYLOIL® which is manufactured and/or distributed by CastNylons Limited. A cutter roller formed from an oil-impregnated plasticcan be formed from substantially the same methods as used to make cutterrollers from UHMW or DELRON® (e.g. CNC milling). The lifespan of aconventional cutter has only been 4-6 months. By contrast, anexperimental cutter roller manufactured in accordance with thisinvention has been in operation for nearly a year.

The CNC machining process for making the cutter roller has also beenimproved. Normally, after you have the cutter roller at the correctdiameter, you bore the roller and then put the cutter roller on a CNCmachine to cut out material that leaves a plurality of narrow walls 111that define the product patterns 112. After that, you put in thestainless steel shaft (not shown) through the length of the cutter 100,and then cut in a profile or crown using a lathe and a curved template,the crown permitting the cutter to fully engage the width of the frontroller when held across its span by its axial shaft.

It has been discovered that it is better to cut the crown into thecutter roller 100 before cutting walls 11 and corresponding productpatterns 112 into the cutter roller 100 with the CNC machine. In theconventional sequence, the lathe tool tends to leave chips or burrs onthe walls 111 that define the product patterns 112. Those chips or burrsmust be cleaned off by hand. By boring out the roller 100 and puttingthe shaft in first, and then adding the crown via a lathing process, andthen moving to the CNC machine, there is no need to clean the chips orburrs and the overall products is more dimensionally precise andfunctions better in use.

FIG. 11 is a block diagram illustrating the steps of a preferredembodiment of manufacturing a cutter roller 100. As shown, the preferredmethod includes the following steps: Step 201—providing a roller blankof a desired diameter; Step 202—boring an axial aperture in the rollerblank; Step 203—installing a shaft in the axial aperture of the rollerblank; Step 204—creating a crown on the roller blank by removingmaterial from the roller blank to create a crowned roller blank; andStep 205—machining the cutting pattern into the crowned roller blank tocreate a finished cutter roller.

The just described embodiment is but one of many possible embodiments ofthe invention, which invention is described in the following claims.

1-3. (canceled)
 4. A method of forming a cutter roller for a doughsheeter comprising the steps of: providing a roller blank of a desireddiameter; boring an axial aperture in the roller blank; installing ashaft in the axial aperture of the roller blank; creating a crown on theroller blank by removing material from the roller blank to create acrowned roller blank; and machining the cutting pattern into the crownedroller blank to create a finished cutter roller.
 5. The method offorming a cutter roller of claim 4 wherein the roller blank is formedfrom an oil-impregnated plastic.